Jungheinrich EJC B16, EJC B14 User Manual

		EJC B14 / B16		09.05 -
		Operating instructions						G
		50470432
		03.11					EJC B14
							EJC B16

Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg

Manufacturer or his authorized representative in the Community

Type	Option	Serial No.	Year of
			construction

EJC B14

EJC B16

Additional information

Authorised signatory

Date

GEU Declaration of Conformity

The signatories hereby certify that the specified powered industrial truck conforms to the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (ElectroMagnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each case to compile the technical documentation.

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Foreword

Notes on the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.

The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following graphics:

DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.

NOTE

Indicates a material hazard. Failure to comply with this instruction may result in material damage.

ZUsed before notices and explanations.

t Indicates standard equipment

oIndicates optional equipment

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

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Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - Germany

Tel: [phone]

www.jungheinrich.com

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Table of Contents
A	Correct Use and Application ...................................................	9
1	General....................................................................................................	9
2	Correct application...................................................................................	9
3	Approved application conditions..............................................................	9
4	Proprietor responsibilities ........................................................................	10
5	Adding attachments and/or accessories..................................................	10
B	Truck Description ....................................................................	11
1	Application ...............................................................................................	11
1.1	Truck models and rated capacity.............................................................	11
2	Assemblies and Functional Description...................................................	12
2.1	Assembly Overview .................................................................................	12
2.2	Functional Description .............................................................................	14
3	Technical Specifications ..........................................................................	15
3.1	Performance data ....................................................................................	15
3.2	Dimensions..............................................................................................	16
3.3	Standard mast version EJC B14 .............................................................	17
3.4	Standard mast version EJC B16 .............................................................	17
3.5	Weights....................................................................................................	18
3.6	Tyre type..................................................................................................	18
3.7	EN norms.................................................................................................	19
3.8	Conditions of use.....................................................................................	20
3.9	Electrical requirements ............................................................................	20
4	Identification points and data plates ........................................................	21
4.1	Data plate ................................................................................................	22
4.2	Truck load chart.......................................................................................	23
C	Transport and Commissioning ................................................	25
1	Lifting by crane ........................................................................................	25
2	Transport .................................................................................................	26
3	Using the Truck for the First Time ...........................................................	27
4	Adjustment of wheel arms .......................................................................	27
D	Battery - Servicing, Recharging, Replacement .......................	29
1	Safety Regulations Governing the Handling of Lead-Acid Batteries .......	29
2	Battery types............................................................................................	31
3	Exposing the battery................................................................................	32
4	Charging the battery ................................................................................	33
4.1	Charging the battery with a stationary charger........................................	33
5	Battery removal and installation ..............................................................	35

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E	Operation ................................................................................	37
1	Safety Regulations for the Operation of the Forklift Truck.......................	37
2	Displays and Controls..............................................................................	38
2.1	Battery discharge indicator ......................................................................	41
3	Starting up the truck ................................................................................	42

3.1Checks and operations to be performed before starting daily operation . 42

3.2	Preparing the truck for operation .............................................................	43
3.3	Parking the truck securely .......................................................................	44
3.4	Battery discharge monitor........................................................................	44
4	Industrial Truck Operation .......................................................................	45
4.1	Safety regulations for truck operation......................................................	45
4.2	Emergency Disconnect, Travel, Steering, Braking ..................................	47
4.3	Lifting, transporting and depositing loads ................................................	52
5	Troubleshooting.......................................................................................	53
5.1	Truck does not start.................................................................................	54
5.2	Load cannot be lifted ...............................................................................	54
6	Operating the truck without its own drive system ....................................	55
7	Load handler emergency lowering ..........................................................	56
8	Optional equipment .................................................................................	57
8.1	Fork tines.................................................................................................	57
8.2	CanCode keypad.....................................................................................	59
8.3	CANDIS display instrument .....................................................................	63
F	Industrial Truck Maintenance ..................................................	65
1	Operational Safety and Environmental Protection...................................	65
2	Maintenance Safety Regulations.............................................................	65
3	Servicing and Inspection .........................................................................	70
4	Maintenance checklist .............................................................................	71
5	Lubricants and Lubrication Schedule ......................................................	74
5.1	Handling consumables safely..................................................................	74
5.2	Lubrication Schedule ...............................................................................	76
5.3	Consumables...........................................................................................	77
6	Maintenance and repairs .........................................................................	78
6.1	Preparing the truck for maintenance and repairs ....................................	78
6.2	Removing the front panel ........................................................................	79
6.3	Checking the hydraulic oil level ...............................................................	80
6.4	Check the gear oil level ...........................................................................	81
6.5	Replacing the gauze filter, flushing the gauze filter .................................	81
6.6	Checking electrical fuses.........................................................................	82
6.7	Restoring the truck to service after maintenance and repairs .................	83
7	Decommissioning the industrial truck ......................................................	84
7.1	Prior to decommissioning ........................................................................	84
7.2	Action to be taken during decommissioning ............................................	86
7.3	Restoring the truck to service after decommissioning .............................	87
8	Final de-commissioning, disposal............................................................	87
9	Safety tests to be performed at intervals and after unusual incidents .....	88

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	Appendix
	JH Traction Battery Operating Instructions
Z	These operating instructions apply only to Jungheinrich battery models. If using
	another brand, refer to the manufacturer's operating instructions.

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0506.GB

A Correct Use and Application

1General

The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.

It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.

2Correct application

NOTE

The maximum load and load distance are indicated on the load chart and must not be exceeded.

The load must rest on the load handler or be lifted by an attachment approved by the manufacturer.

The load must rest on the back of the fork carriage and centrally between the forks.

–Lifting and lowering of loads.

–Transporting lowered loads.

–Do not travel with a raised load (>500 mm).

–Do not carry or lift passengers.

–Do push or pull load units.

3Approved application conditions

–Operation in industrial and commercial environments.

–Permissible temperature range 5°C to 40°C.

–Operation only on secure, level surfaces with sufficient capacity.

–Operation only on routes that are visible and approved by the proprietor.

–Negotiating inclines up to a maximum of 16 %.

–Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.

–Operation in partially public traffic.

ZSpecial equipment and authorisation is required if the truck is to be used in extreme conditions.

The truck is not authorised for use in areas at risk of explosion.

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4Proprietor responsibilities

For the purposes of the present operating instructions the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the industrial truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user and third parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all users have read and understood these operating instructions.

NOTE

Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.

5Adding attachments and/or accessories

Adding accessories

The mounting or installation of additional equipment which affects or enhances the performance of the forklift truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained.

Local authority approval does not however constitute the manufacturer’s approval.

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B Truck Description

1Application

The EJC B14 / B16 is a four wheel, tiller guided electric truck with a steered drive wheel and adjustable wheel arms.

It is designed for use on level floors to lift and transport goods. Open bottom pallets or roll cages can be lifted.

1.1Truck models and rated capacity

The rated capacity depends on the model. The rated capacity can be derived from the model description.

EJCB14

EJC Model name

BSeries

14 Rated capacity x 100 kg

The rated capacity does not generally match the permissible capacity. The capacity can be found on the load chart attached to the rack.

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2Assemblies and Functional Description

2.1Assembly Overview

2			1
3		3	4
	5
			6
7			8
9, 10
			11
12			13
14

16		15
		17
		18
Item	EJC B14/B16	Name
2	t	Slow travel button
1	t	Mast
3	t	Travel switch
4	t	Mast guard
	o	Mesh for cold store operation
5	t	Collision safety switch
6	t	Battery panel
7	t	Tiller
8	t	Emergency Disconnect (battery switch)
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9		t		Battery charge / discharge unit
		o		CANDIS display instrument
10		o		CANCODE keypad
11		o		Load backrest
12		t		Key switch
13		t		Fork tines
14		o		Document storage compartment
16		t		Drive wheel
17		t		Front panel
18		t		Castor wheel
t= Standard equipment			o= Optional equipment

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2.2Functional Description

Safety Mechanisms

–An enclosed, smooth truck geometry with rounded edges ensures safe handling of the truck.

–The wheels are surrounded by a solid skirt.

–Pressing the Emergency Disconnect rapidly cuts out all electrical functions in hazardous situations.

Hydraulic system

–Lifting and lowering are activated via the lift and lower buttons.

–When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder.

–If the truck is fitted with a duplex twin-stage mast (ZZ) or a triplex telescopic mast (DZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck.

Drive system

–A fixed DC motor actuates the drive wheel via a bevel spur gearbox.

–The electronic traction controller ensures smooth drive motor speed control and hence smooth travel, powerful acceleration and electrically controlled braking.

Tiller

–All travel and lift operations can be performed sensitively without having to reach.

–The driver steers with a tiller:

–The drive system can be pivoted +/- 90°.

Electrical system

–24 volt system.

–Electronic traction control is standard.

Controls and Displays

–Ergonomic controls ensure fatigue-free operation for sensitive application of the travel and hydraulic operations.

–The battery discharge indicator shows the available battery capacity.

Mast

–The maximum strength steel sections are narrow, allowing for outstanding fork visibility in particular with the three-stage mast.

–The lift rails and the fork carriage run on permanently-lubricated and hence maintenance-free angled rollers.

Fork tines

– Alternatively, the truck can be fitted with 2A fork tines.

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3Technical Specifications

ZTechnical data specified in accordance with VDI 2198. Technical modifications and additions reserved.

3.1Performance data

	Description	EJC B14		EJC B16
Q	Rated capacity	1400		1600		kg
	Travel speed	6,0	/ 6,0	6.0	/ 6.0	km/h
	w / w.o. rated load
	Lift speed	15	/ 23	14	/ 23	cm/sec
	with / without rated load
	Lower speed	44	/ 42	40	/ 40	cm/sec
	with / without rated load
	Max. gradeability	8 / 16		7 / 16		%
	w / w.o. rated load

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3.2Dimensions

h4

h3

		l	h1
	h5
			c
	h8
	h2	Q	m2
	s	20	l2
			y
			l1

Ast

b4	b5	B
		W
		a

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		EJC B14	EJC B16
c	Load centre distance	600	600	mm
x	Load distance	667	667	mm
y	Wheelbase	1409	1409	mm
l1	Length with fork length 1150 mm	2050	2050	mm
l2	Fork length	900	900	mm
	including fork shank
b4	Dimension between the wheel	900 - 1350	900 - 1350	mm
	arms (adjustable)
b5	Width across forks	316 - 900	316 - 900	mm
m2	Ground clearance centre	30	30	mm
	wheelbase
Ast	Working width 1000x1200	2162	2162	mm
	crosswise 1)
Ast	Working aisle width for	2362	2362	mm
	pallet 800x1200 longit. 1)
Wa	Turning radius	1629	1629	mm
	lowered / raised
1) wit DZ mast: +4 mm

3.3Standard mast version EJC B14

	Description	Telescopic mast		Twin-reach mast		Triplex Mast (DZ)
		(ZT)		(ZZ)
h1	Height 1)	1700	- 2600	1700	- 2600	1800	- 2250	mm
h2	Free lift 2)	100			-		-	mm
h3	Lift	2500	- 4300	2500	- 4300	4000	- 5350	mm
h4	Max. height 4)	3060	- 4860	3060	- 4860	4560	- 5910	mm
h5	Free lift 3) 5)		-	1140 - 2040		1240	- 1690	mm

3.4Standard mast version EJC B16

	Description	Telescopic mast		Twin-reach mast		Triplex Mast (DZ)
		(ZT)		(ZZ)
h1	Height 1)	1700	- 2600	1700	- 2600	1800	- 2250	mm
h2	Free lift 2)	100			-		-	mm
h3	Lift	2400	- 4200	2400	- 4200	3900	- 5250	mm
h4	Max. height 4)	2960	- 4760	2960	- 4760	4460	- 5810	mm
h5	Free lift 3) 5)		-	1140 - 2040		1240	- 1690	mm

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3.5Weights

		EJC B14	EJC B16
	Net weight excl. battery	1010	1050	kg
	Axle load, w. load	810/1820	870/2030	kg
	front/rear + battery
	Axle load, w.o. load	830/430	840/460	kg
	front/rear + battery
	Battery weight	243-297	243-297	kg

3.6Tyre type

		EJC B14	EJC B16
	Tyre size, drive	230x70	230x70	mm
	Tyre size, load section	85x75	85x75	mm
	Castor wheel	125x50	125x50	mm
	Wheels, number front/rear	1x+1/ 4	1x+1/ 4
	(x = driven)

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3.7EN norms

Noise emission level

– EJC B14 / B16: 67 dB(A)

in accordance with EN 12053 as harmonised with ISO 4871.

ZThe noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the level of the driver's ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein.

ZNo changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

WARNING!

Medical equipment can be damaged by non-ionised radiation

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions. Consult with a doctor or the medical equipment manufacturer to clarify whether it can be used near the industrial truck.

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3.8Conditions of use

Ambient temperature

– operating at 5°C to 40°C

ZSpecial equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations.

3.9Electrical requirements

The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.

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4Identification points and data plates

19 20

21

21

22

23

24

25

26 27

V

JU

N

G

H

EI

N

RIC

H

	Item	Description
	19	"Do not reach through the mast" warning
	20	“Do not step under the load handler” warning
	21	Attachment points for lifting by crane (with ZZ mast in the middle)
	22	Truck data plate
	23	Decal: “No passengers”
	25	Test plaque
	24	Capacity
	26	Serial number
03.11 EN	27	Model name

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4.1Data plate

28

29

30

31

32

33

34

35

36

37

38

39

Item	Description	Item	Description
28	Type	34	Year of manufacture
29	Serial number	35	Load centre (mm)
30	Rated capacity (kg)	36	Output
31	Battery voltage (V)	37	Min./max. battery weight (kg)
32	Net weight w.o. battery (kg)	38	Manufacturer
33	Option	39	Manufacturer’s logo

ZFor queries regarding the truck or ordering spare parts always quote the truck serial number (29).

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4.2Truck load chart

	X.XXXX.XX.XX	40
3600	1105
	600

The load chart (40) indicates the maximum capacity Q (in kg) for a given load centre D (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.

Example of calculating the maximum capacity:

With a load centre of gravity distance C of 600 mm and a maximum lift height H of 3600 mm. the max. capacity Q is 1105 kg.

The arrow shaped marks ("41" and "41") on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (21).

41

41

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C Transport and Commissioning

1Lifting by crane

WARNING!

Improper lifting by crane can result in accidents

The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane.

Prevent the truck from striking other objects when it is being raised, and avoid any involuntary movements. If necessary secure the truck with guide ropes.

XThe truck should only be handled by people who are trained in using lifting slings and tools.

XWear safety shoes when lifting the truck by crane. XDo not stand under a swaying load.

XDo not walk into or stand in a hazardous area.

XAlways use lifting gear with sufficient capacity (for truck weight see truck data plate).

XAlways attach the crane slings to the prescribed strap points and prevent them from slipping.

XUse the lifting gear only in the prescribed load direction.

XCrane slings should be fastened in such a way that they do not come into contact with any attachments when lifting.

Lifting the truck by crane

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Requirements

– Park the truck securely, (see "Parking the truck securely" on page 44).

Tools and Material Required

– Lifting gear

– Crane lifting gear

Procedure

• Secure the lifting slings to the strap points (21).

The truck can now be lifted by crane.

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2Transport

WARNING!

Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious accidents.

XLoading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements must be made and appropriate safety measures adopted.

XThe truck must be securely fastened when transported on a lorry or a trailer. XThe lorry / trailer must have fastening rings.

XUse wedges to prevent the truck from moving.

XUse only tension belts or tie-down straps or with sufficient strength.

42

42

Securing the truck for transport

Tools and Material Required

– Tension belts/tie down straps

Procedure

•Move the truck onto the transporting truck.

•Park the truck securely, (see "Parking the truck securely" on page 44).

•Strap the belts (42) around the truck and tension them sufficiently.

The truck can now be transported.

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3Using the Truck for the First Time

CAUTION!

Only operate the truck with battery current. Rectified AC current will damage the electronic components. Cable connections to the battery (tow leads) must be less than 6 m long and have a minimum cross-section of 50 mm².

Procedure

•Check the equipment is complete.

•If necessary install the battery, (see "Battery removal and installation" on page 35)

•Charge the battery, (see "Charging the battery" on page 33).

The truck can now be started, (see "Starting up the truck" on page 42)

NOTE

Cold store trucks

XTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast.

XIf a truck with cold store oil is used outside the cold store, the lowering speeds may increase.

4Adjustment of wheel arms

The distance between the wheel arms is adjustable.

WARNING!

The adjustment of wheel arms must only be performed by a trained service personnel.

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D Battery - Servicing, Recharging,

Replacement

1Safety Regulations Governing the Handling of Lead-Acid Batteries

Maintenance personnel

Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

Fire protection

Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the truck. The room must be ventilated. Fire protection equipment must be on hand.

Battery maintenance

The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease.

CAUTION!

Before closing the battery panel make sure that the battery cable cannot be damaged. There is a risk of short circuits with damaged cables.

Battery disposal

Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.

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